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Capacity TJ5000 DOT, Operator'S Handbook Manual

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Trailer Jockey Operators Handbook

1

S

ECTION

 1. 

I

NTRODUCTION

1-1  G

ENERAL

This handbook contains information designed to familiarize
the operator with the controls and operation of the Trailer
Jockey. Be sure the operator is completely familiar with all
controls and indicators and their functions BEFORE attempt-
ing to operate the tractor. Failure to do so could cause hazard-
ous conditions to develop.

Figure 1. Truck Dimensions

Summary of Contents for TJ5000 DOT

Page 1: ...c 401 Capacity Drive Longview TX 75604 1 800 323 0135 WARNING Failure to read understand and fully comply with the important information contained in this Operator s Handbook may result in hazardous conditions or cause a hazardous condition to develop C A P A C I T Y ...

Page 2: ......

Page 3: ...5 2 Cold Weather Starting Aids 21 3 6 Pre Operation Checks 22 3 6 1 Proper Seat Belt Usage 22 3 6 2 Steering 22 3 6 3 Brakes and Transmission 23 3 6 4 Final Checks 23 3 7 Driving Precautions 24 3 8 If You Have A Problem 25 3 9 Engine Operation 26 3 9 1 Stopping the Engine 26 3 10 Transmission Operation 27 3 10 1 Pushbutton Shift Selector Operation 28 3 10 2 R Reverse 29 3 10 3 N Neutral 29 3 10 4 ...

Page 4: ...ce Procedures 39 4 4 1 Fluid Levels 39 4 4 2 Engine Oil and Filter Changes 39 4 4 3 Regeneration 40 4 4 4 Checking Transmission Fluid Level 42 4 4 5 Transmission Fluid and Filter Changes 43 4 4 6 Hydraulic System Fluid 43 4 4 7 Battery Service 43 4 5 Diagnostics 44 4 5 1 System Diagnostics 44 4 5 2 Driver Initiated Diagnostics 44 4 5 3 Manual Diagnostic 44 4 5 4 Fault Display 45 4 5 5 Transmission...

Page 5: ...y serious injury or possibly death Pay special attention to items identified with the warning label A caution advises you of conditions that could result in dam age to your vehicle or property Study this manual carefully Do not operate your vehicle until you are completely familiar with the contents of this manual Always retain this manual in your vehicle for reference If you sell the vehicle make...

Page 6: ... electrical accessories can result in circuit overload conditions and cause electrical damage and or fire in your vehicle Failure to use these locations for additional electrical connections will void the factory warranty Before welding on any vehicle equipped with an electronic engine ISB ISC QSB QSC CAT3126 power must be disconnected from the engine computer This can be done at the battery or at...

Page 7: ...olved in individual problems between you your dealer or Capacity of Texas Inc To contact the NHTSA you may either call the Auto Safety Hotline toll free at 800 424 9393 or write to them at NHTSA U S Department of Transportation Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline or at the NHTSA website at www nhtsa dot gov Notice To comply with env...

Page 8: ......

Page 9: ...ned to familiarize the operator with the controls and operation of the Trailer Jockey Be sure the operator is completely familiar with all controls and indicators and their functions BEFORE attempt ing to operate the tractor Failure to do so could cause hazard ous conditions to develop Figure 1 Truck Dimensions ...

Page 10: ...rnesses Cooling Heavy duty fin and tube construction radiator filled with 50 50 solution of permanent type antifreeze Transmission oil cooler mounted in front of radiator Air System 15 2 CFM 4 4 cmm compressor three tank reservoir system Brakes Air brakes on all wheels Parking emergency spring type brakes on rear wheel Tractor trailer protection valve and color coded air lines with glad hand brack...

Page 11: ...Trailer Jockey Operators Handbook 3 1 3 MAJOR COMPONENTS Figure 2 illustrates the major components of the Trailer Jockey Figure 2 Major Components ...

Page 12: ... Lighter fuels can reduce fuel economy and possibly damage fuel system components Cummins recommends the use of ASTM number 2D fuel for optimum engine performance The engine in your vehicle has been optimized to meed U S Environmental Protection Agency EPA regulations To meet these regulations ultra low sulfur diesel fuel is required If ultra low sulfur diesel fuel is not used the engine may not m...

Page 13: ...ex numbers in the figure correspond to the item numbers in the table The operator should know the location and function of each control and indicator and have a thorough knowledge of their functions before operating the tractor REMEMBER A careful operator is the best safety device The Trailer Jockey is equipped with an operator seat belt The seat belt should be worn at all times during operation t...

Page 14: ...gure 2 1 Controls and Indicators Table 2 1 Controls Indicators Item Name Function 1 Status LED Panel 1 Multiple LEDs indicate various conditions Refer to Figure 2 2 for more information 2 Tachometer Indicates engine speed in RPM ...

Page 15: ... Normal reading should be 10 Key Switch Three position key operated switch In OFF position electrical system is de energized and key can be removed In ON position the electrical system is energized In START position starter is engaged to start engine Release to ON position when engine is started 11 Air System Pressure Gauge 2 Indicates pressure in air brake system in PSI and KPa Normal reading sho...

Page 16: ...b Rotary knob that adjusts the temperature level of the cab heater 25 Heater Fan Control Knob Rotary knob that sets the heater fan HIGH LOW or OFF 26 Panel Lights Control Knob Rotary knob that adjusts the brightness of the dash control lights 27 Brake Pedal Pedal that controls the application of the brakes Depress pedal to apply brakes Brakes should be applied slowly except in emergency situations...

Page 17: ...ol Pushbutton control pad that controls the transmission Refer to Figure 2 3 for details 32 Fifth Wheel Control Lever Three position control lever that positions the fifth wheel LOWER moves fifth wheel down HOLD Maintains fifth wheel elevation RAISE Elevates fifth wheel 33 Trailer Air Supply Valve Push pull knob that applies air pressure to trailer brake system when depressed pull knob out to evac...

Page 18: ...T Table 2 1 Controls Indicators Cont Item Name Function 35 Seat Position Control Lever that is used to adjust front to rear position of the seat 36 Seat Suspension Lock Lever that is used to control the seat suspension 37 Seat Back Control Knob Knob that can be turned to adjust the tilt of the seat back 38 Lumbar Control Switch Switch that controls the adjustment of the lumbar support 39 Seat Heig...

Page 19: ...he anti lock brake system ABS 42 Engine Diagnostic Regeneration Switch Dual purpose switch When engine is turned off activates engine diagnostic mode refer to XREF for more information When engine is turned on activates the engine regeneration cycle refer to XREF for more information 43 Diagnostic Connector Deutsch connector that is used to connect engine diagnostic computer to truck for maintenan...

Page 20: ...dicators Cont Table 2 1 Controls Indicators Cont Item Name Function 44 Air Filter Indicator Indicates the restriction clogging of engine air filter measured in inches of Mercury in Hg Press reset button on top of indicator after replacing air filter ...

Page 21: ...Trailer Jockey Operators Handbook 13 Figure 2 2 Dash LED Indicators ...

Page 22: ...trailer s ABS system is detected 11 ATC Warning Light Illuminates when a fault with the automatic traction control ATC system is detected 12 Stop Engine Warning Light Illuminates when conditions exist that could seriously damage the engine Operator should turn the engine off immediately 13 Engine Warning Light Illuminates when one or more of the following conditions exist Low Oil Pressure Engine C...

Page 23: ...urn engine off to prevent possible engine damage and check oil level 28 Coolant Temperature Light Illuminates when coolant temperature has risen to an unsafe level Operator should turn engine off to prevent possible engine damage and check coolant level and water pump 29 Low Coolant Light Illuminates when coolant level falls below safe level Operator should turn engine off to prevent possible engi...

Page 24: ...tion mode 3 Mode Select Button Activates special operation modes for the transmission 4 Shifter Buttons When transmission is in D drive pressing these buttons shifts the transmssion into higher or lower gears Also used to enter transmission s diagnostic mode See XREF for more information 5 Reverse Select Button Shifts the transmission into reverse 6 Neutral Select Button Shifts the transmission in...

Page 25: ...mulate on floor of cab or exterior steps and walkways A slippery surface is hazard ous This vehicle has been engineered and manufactured to be as safe and trouble free as possible Vehicle design and the parts used to manufacuture this vehicle undergo extensive testing and research to guarantee that acceptable safe service lift is realized However the vehicle owner plays an important part and deter...

Page 26: ...on and daily preventative mainte nance operations listed later in this book Use lubricants and antifreeze solutions suitable for lowest expected temperatures Note and comply with any special instruction tags Be sure that date of delivery and start up is reported to factory on war ranty registration card to validate warranty Fill in and mail engine warranty registration slip 3 2 2 OPERATOR ORIENTAT...

Page 27: ...visor immediately Pre operation inspection should include but not be limited to the following items leaks frayed hoses worn insulation loose or missing parts tire damage proper tire inflation guards and other protective devices in place and secure 3 4 VEHICLE REFUELING Do not smoke when refueling the vehicle Keep all cigarettes cigars pipes sparks flames or other sources of possible ignition at le...

Page 28: ... by a trailer Exhaust fumes can cause sickness and death If necessary to start an engine in an enclosed area be sure to provide adequate ventilation To avoid loss of vehicle control and possible personal injury never operate the vehicle when insufficient air pressure less than 70 PSI 483 KPa is indicated for either system since the volume of air required to stop the vehicle may be greater than tha...

Page 29: ... as the oil has drained off the moving parts Do not start engine and immediately accelerate the engine or put it under load It needs to be run at low idle for a few minutes to warm up and lubricate itself before being accelerated or placed under load The transmission is programmed to restrict full operation in temperatures below 19 ºF 7 ºC until the transmission fluid reaches suitable operating te...

Page 30: ...that you can sit up straight After adjustment make sure the tether belts are snug b Pick up the latch plate and pull the belt across you Do not let it get twisted c Push the latch plate into the buckle until it clicks Make sure the release button on the buckle is positioned for easy access in the event you need to release it quickly d To unfasten the belt press the red release button on the buckle...

Page 31: ... brakes to make sure you will be able to stop and stay stopped Be sure you can control direction of travel and speed Shift the transmission control lever in both directions The brake must be applied when shifting from neutral to forward or reverse With the transmission in neutral and the brakes applied accelerate and decelerate the engine to make sure the throttle works correctly and returns to id...

Page 32: ... and on slopes Keep your speed slow enough so you are in com plete control at all times Give loaded vehicles the right of way Follow your employer s traffic rules on the job Watch out for other vehicles Do not make sudden maneuvers with elevated trailer Avoid crossing obstacles such as ridges curbs lumber railroad tracks and chocks Before backing up check that area behind vehicle is clear of peopl...

Page 33: ...rty damage when manually releasing the spring brakes be sure to block the wheels so that vehicle cannot move when the brakes are released Under no circumstances should a spring brake chamber assembly be disassembled without following the procedures described in the service manual Bypassing these procedures may result in severe personal injury or death To manually release parking brakes for towing ...

Page 34: ...ires and lines for engine cooling brake system fuel system power steering system and electrical system Heat damage to hoses wires or lines may cause vehicle malfunction that could result in property damage or severe personal injury 3 9 1 STOPPING THE ENGINE Shift the transmission to neutral set the parking brake and turn the key off Engines which are hot or have been under a heavy load should be a...

Page 35: ...ns The transmission does it for you The pushbutton shift selector also provides the ability to monitor transmission fluid levels and display diagnostic codes Having a thorouogh knowledge of the shift selector positions available ranges and when to select them will make vehicle control and your job easier Select lower ranges when descend ing long grades to reduce wear and tear on service brakes Vis...

Page 36: ... in the lowest available forward range and advance automatically to the highest range Up arrow Press this button when in Drive to request the next higher range Continuously pressing the up arrow will request the highest range possible Down arrow Press this button when in Drive to request the next lower range Continuously pressing this button will request the lowest range possible MODE This button ...

Page 37: ... Neutral when starting the engine to check vehicle accessories and for extended periods of engine idle operation longer than five minutes The transmission will automati cally select N when starting the engine 3 10 4 D DRIVE Drive gear may not be attained due to an active inhibitor Apply service brakes when selecting D Drive to prevent unexpected vehicle movement and because a service brake inhibit...

Page 38: ...d neutral to reverse forward to reverse reverse to forward A safety device on the Trailer Jockey requires that the brakes be applied to shift out of neutral If this device is not operating repair or adjust it at once If you leave the vehicle and the engine is running the vehicle can move unexpectedly and you or others could be injured If you must leave the engine running do not leave the vehicle u...

Page 39: ...t could result in a false or improper coupling and cause damage to the Trailer Jockey fifth wheel and or trailer a Raise fifth wheel if necessary to pick up the trailer slightly when backing under trailer b Back under trailer until the fifth wheel latches securely c Raise the trailer landing gear just off the ground Place shift selector in D and make test pull Move forward just enough to be sure t...

Page 40: ...Trailer Jockey with trailer on public roads the fifth wheel manual secondary lock must be used Check to see that it is properly engaged When operating this vehicle on public highways the fifth wheel highway lock must be engaged and the fifth wheel must be in the lowered position with the trailer landing gear cranked up to comply with overall height regulations The PTO should be disengaged when dri...

Page 41: ...Jockey away from the trailer 3 14 SHUTDOWN a When the Trailer Jockey is positioned in its parking area pull out on the yellow parking brake knob to apply the parking brakes b Turn the ignition key to OFF to shut down the engine c If the vehicle is to remain idle for several hours the fuel tank should be filled to prevent condensation 3 15 TOWING Any time the Trailer Jockey is to be towed the drive...

Page 42: ...he display starts in odometer mode showing the vehicle s cumulative mileage To switch between miles and kilometers press the Set button 3 16 2 TRIP ODOMETER MODE The display incorporates two independent trip odometers identified as TRIP1 and TRIP2 To reset a trip odometer press the Set button while in trip odometer mode To switch between miles and kilometers press the Set button 3 16 3 HOURMETER M...

Page 43: ...enance should seldom be required 4 2 TILTING THE CAB The cab can be tilted forward to gain access to the engine transmission and hydraulics Never get under a raised cab unless the safety latch bar is engaged Stay clear of descending cab and platform a Push lever down on cab lift pump to raise cab b Be sure safety latch bar is locked securely into any one of the six holding positions before proceed...

Page 44: ...on changing the engine oil 4 3 2 DAILY MAINTENANCE Never remove cap from hot radiator Allow radiator to cool Record hourmeter reading Check coolant level and add coolant if necessary use cau tion Check transmission oil level and add oil if necessary engine running Check engine oil level add oil if necessary engine stopped Check power steering oil level and add oil if necessary Check all belts for ...

Page 45: ...gine oil and filter Change hydraulic oil filter Check wheel nut torque Change transmission external filter Check fuel filters when fuel reaches 1 2 from top of clear bowl Check adjustment on all brakes with manual slack adjuster 4 3 5 QUARTERLY MAINTENANCE The following checks should be made quarterly or after every 500 hours of operation Check air cleaner restriction and replace filter if necessa...

Page 46: ...ir tank Check Dura Ride center bearing Check Dura Ride air bags Check Dura Ride height adjustment 4 3 7 2000 HOUR MAINTENANCE The following checks should be made after every 2000 hours of operation Flush cooling system Check viscous vibration damper Steam clean engine Check radiator hoses Inspect crankcase ventilation filter Replace if necessary 4 3 8 OVERHEAD SET ADJUSTMENT Overhead set adjustmen...

Page 47: ...main hydraulic system oil level may be visually checked by sight gauge at the right side of the Trailer Jockey The oil level must be maintained above the half way mark when the fifth wheel is lowered The main hydraulic system is pressurized Remove the pres sure cap slowly to relieve the pressure before adding oil Be sure the area around the cap is clean before removing it 4 4 2 ENGINE OIL AND FILT...

Page 48: ... necessary and are not recommended 4 4 3 REGENERATION There are two types of regeneration that occur as the engine operates Passive regeneration occurs naturally when the heat of exhaust burns off the soot Active regeneration becomes nec essary when the temperature is too low to completely burn off the soot If soot accumulates in the filter a parked regenera tion cycle is required The driver is al...

Page 49: ... to a safe area and stop the truck 2 Set parking brake and shift transmission to N Neu tral 3 Verify that no other indicator lights are illuminated in particular the Check Engine light 4 Depress the regeneration switch on the right side of the cab control panel The engine speed will increase to approximately 1600 RPM Once the engine temperature has been raised to an appropriate level the regenera ...

Page 50: ... arrow and Down arrow buttons After a few seconds the digital display will cycle between three codes as listed in Table 4 1 For example a display that flashes OL LO 02 is two quarts low Table 4 1 Transmission Fluid Level Display Codes Sequence Code Description 1 OL Fluid Oil Level being displayed 2 LO Fluid Level Low HI Fluid Level High Fault 3 0x Number of quarts to be added or number of quarts o...

Page 51: ...scribed range Once oil is up to normal operating temperature Recheck oil level add oil if necessary Flush oil cooler and lines thoroughly when changing or over hauling the transmission 4 4 6 HYDRAULIC SYSTEM FLUID Change oil and filter at prescribed intervals Check for leaks Flush reservoir suction screen lines and cylinders thoroughly when replacing or rebuilding damaged parts especially pumps an...

Page 52: ...ad AUTO indicating it is in automatic diagnostic mode d Press the Set button again to start the test The gauges will all move in unison to mid scale to full scale back to mid scale and then back to zero All indicator LEDs Figure 2 2 will flash and then turn on 4 5 3 MANUAL DIAGNOSTIC This function is similar to the Driver Initiated Diagnostic mode except the operator can select individual modules ...

Page 53: ...Press the Set button twice until the display reads FAULTS indicating it is in fault code mode d Press the Set button The first active fault will be dis played e After the first fault is recorded press the Mode button to cycle to the second fault f Repeat the process until the display reads FAULTS indicating that all codes have been displayed Table 4 2 CM850 System Fault Codes Fault Code Reason Eff...

Page 54: ...ote accelerator will not operate Remote accelerator position will be set to zero percent 974 4 Remote Throttle Pedal Lever Position Sensor Circuit Shorted Low Low signal voltage detected at the remote Accelerator Pedal Lever Position Circuit Remote accelerator will not operate Remote accelerator position will be set to zero percent 110 3 Engine Coolant Temperature Sensor Circuit Shorted High High ...

Page 55: ... the intake manifold air temperature sensor Possible white smoke Fan will stay ON if controlled by ECM No engine protection for intake manifold temperature 105 0 Intake Manifold Air Temperature Number 1 High Critical Intake Manifold Air Temperature Signal indicates intake manifold air temperature is above the engine protection critical limit Power and or speed derate and possible engine shutdown i...

Page 56: ...1 Engine Coolant Level Low Critical Engine coolant sensor signal indicates that the coolant level is below the engine protection limit None on performance 84 2 Vehicle Speed Sensor Circuit Data Incorrect The ECM lost the vehicle speed signal Engine speed limited to Maximum Engine Speed without VSS Cruise control gear down protection and the road speed governor could possibly not work 84 01 Vehicle...

Page 57: ...k shaft Supply Voltage Circuit Shorted Low Low voltage detected on the ECM voltage supply line to the engine speed sensor Possible hard starting and rough running 639 9 SAE J1939 Multiplexing PGN Timeout Error The ECM expected information from a multiplexed device but did not receive it soon enough or did not receive it all At least one multiplexed device will not operate properly 639 13 SAE J1939...

Page 58: ...lenoid Valve Cylinder Number 5 Circuit Open Circuit High resistance detected on Injector Number 5 Circuit or no current detected at Number 5 injector driver or return pin when the voltage supply at the harness is on Engine can possibly misfire or run rough 653 5 Injector Solenoid Valve Cylinder Number 5 Circuit Open Circuit High resistance detected on Injector Number 5 Circuit or no current detect...

Page 59: ...ifficulty in starting the engine Fault information trip information and maintenance monitor data can be inaccurate 629 12 Engine Control Module Warning Internal Hardware Failure Internal ECM failure Possible none on performance or severe derate 629 12 Injector Power Supply Bad Device The ECM measured injector boost voltage is low Possible Low Power Smoke Miss Runs Rough Engine May Not Start or no ...

Page 60: ...e SAE J1939 datalink has been lost None on performance Devices on the SAE J1939 datalink may not operate 97 3 Water in Fuel Sensor Circuit Shorted High High voltage detected at the Water In Fuel Circuit None on performance No water In fuel warning available 97 4 Water in Fuel Sensor Circuit Shorted Low Low voltage detected at the Water in Fuel Circuit None on performance No water in fuel warning a...

Page 61: ... Switch Circuit Data Incorrect An error in the Engine Oil Pressure Switch signal was detected by the ECM Engine will run derated 168 18 Battery Number 1 Voltage Low Warning Voltage detected at ECM power supply pins indicates low ECM supply voltage Engine could possibly die or run rough 168 16 Battery Number 1 Voltage High Warning Voltage detected at ECM power supply pins indicates ECM supply volta...

Page 62: ...er the engine will not start or the engine will not have Starter Lockout Protection 103 16 Turbocharger Number 1 Speed High Warning Level High turbocharger speed has been detected Engine power derate The ECM will use an estimated turbocharger speed 167 16 Electrical Charging System Voltage High Warning Level High voltage detected by the battery voltage monitor feature Amber Warning Lamp illuminate...

Page 63: ... detected at the Turbocharger Compressor Inlet Air Temperature Sensor Circuit Engine power derate 723 7 Engine Speed Position Number 2 Mechanical Misalignment Between Camshaft and Crankshaft Sensors Engine position signal from the engine speed sensor and camshaft position sensor do not match Engine power derate 723 2 Secondary Engine Speed Sensor Error The ECM has detected an error in the camshaft...

Page 64: ...nical System Not Responding Properly or Out of Adjustment Unintended fueling detected in cylinder Number 2 Engine will shut down 652 0 Injector Cylinder Number 3 Mechanical System Not Responding Properly or Out of Adjustment Unintended fueling detected in cylinder Number 3 Engine will shut down 653 0 Injector Cylinder Number 4 Mechanical System Not Responding Properly or Out of Adjustment Unattend...

Page 65: ...94 16 Fuel Pump Delivery Pressure Data Valid but Above Normal Operational Range Moderately Severe Level The ECM has detected fuel pressure in the fuel rail is higher than the commanded pressure None or possible engine noise associated with higher injection pressures especially at idle or light load 1075 3 Fuel Priming Pump Control Signal Circuit Shorted High High signal voltage detected at the Ele...

Page 66: ...M has detected that fuel pressure in the fuel rail is higher than the commanded pressure Possibility hard to start lower power or engine smoke 0 18 Fuel Inlet Meter Device Flow Demand Lower Than Expected The ECM has detected that fuel pressure in the fuel rail is lower than the commanded pressure None or possible engine noise especially at idle or light load 633 31 Fueling Actuator Number 1 Circui...

Page 67: ...rol Circuit Shorted Low Low volt age detected at the EGR Valve Motor Circuit Power removed from the EGR valve motor 2791 3 EGR Valve Control Circuit Shorted High High voltage detected at the EGR Valve Motor Circuit Possible low power EGR motor will be powered down 2791 6 EGR Valve Control Circuit Excessive Current Detected Excessive current detected at the EGR Valve Motor Circuit Possible low powe...

Page 68: ...orted High High signal voltage detected at the EGR Temperature Sensor Circuit EGR valve will be closed 412 4 EGR Temperature Sensor Circuit Shorted Low Low signal voltage detected at the EGR Temperature Sensor Circuit EGR valve will be closed 647 3 Fan Control Circuit Shorted High Open circuit or high voltage detected at the Fan Control Circuit The fan may stay on continuously or not run at all 27...

Page 69: ...om the turbocharger actuator motor 641 7 Variable Geometry Turbocharger Actuator Mechanical system not Responding Properly or Out of Adjustment Turbocharger Actuator not responding or slow to respond Possible low power Power will be removed from the turbocharger actuator motor 641 2 Variable Geometry Turbocharger Number 1 Actuator Position Sensor Out of Calibration Turbocharger actuator failed aut...

Page 70: ...nge Least Severe Level Engine power derate 412 16 EGR Temperature Data Valid but Above Normal Operating Range Moderately Severe Level Engine power derate 110 15 Engine Coolant Temperature High Warning Engine temperature signal indicates engine coolant temperature is above engine protection warning limit Power derate and possible engine shutdown if engine protection shutdown feature is enabled 105 ...

Page 71: ...Normal Range least severe level EGR valve will be closed 641 0 Variable Geometry Turbocharger Actuator Over Temperature Calculated Data Above Normal Range Least Severe Level Possible low power Power to turbocharger actuator will be limited Table 4 2 CM850 System Fault Codes Cont Fault Code Reason Effect ...

Page 72: ...ormal or Shorted to High Source High signal voltage detected at the intake manifold pressure circuit Derate in power output of the engine 102 4 Intake Manifold 1 Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source Low signal voltage or open circuit detected at the intake manifold pressure circuit Derate in power output of the engine 91 3 Accelerator Pedal or Lever Position Sensor...

Page 73: ...e protection for engine coolant temperature 110 4 Engine Coolant Temperature 1 Sensor Circuit Voltage Below Normal or Shorted to Low Source Low signal voltage detected at engine coolant temperature circuit Possible white smoke Fan will stay ON if controlled by ECM No engine protection for engine coolant temperature 110 16 Engine Coolant Temperature Data Valid but Above Normal Operational Range Mod...

Page 74: ... air temperature above engine protection critical limit Progressive power derate increasing in severity from time of alert If Engine Protection Shutdown feature is enabled engine will shut down 30 seconds after red STOP lamp starts flashing 111 3 Coolant Level Sensor 1 Circuit Voltage Above Normal or Shorted to High Source High signal voltage detected at engine coolant level circuit None on perfor...

Page 75: ...rce High voltage detected at sensor supply number 3 circuit Possible hard starting and rough running 84 2 Wheel Based Vehicle Speed Data Erratic Intermittent or Incorrect The ECM lost the vehicle speed signal Engine speed limited to Maximum Engine Speed without VSS parameter value Cruise control Gear Down Protection and Road Speed Governor will not work 84 10 Wheel Based Vehicle Speed Sensor Circu...

Page 76: ...w voltage detected at ambient air temperature circuit None on performance 1347 4 Fuel Pump Pressurizing Assembly 1 Circuit Volt age Below Normal or Shorted to Low Source Low signal voltage detected at the fuel pump actuator circuit Engine will run poorly at idle Engine will have low power Fuel pressure will be higher than commanded 1347 3 Fuel Pump Pressurizing Assembly 1 Circuit Volt age Above No...

Page 77: ... control unit VECU detected a fault with the remote accelerator The engine will not respond to the remote throttle Engine may only idle The primary or cab accelerator may be able to be used 108 2 Barometric Pressure Data Erratic Intermittent or Incorrect The ambient air pressure sensor is reading an erratic value at initial key on Engine power derate 651 5 Injector Solenoid Driver Cylinder 1 Circu...

Page 78: ...ctor Solenoid Driver Cylinder 4 Circuit Current Below Normal or Open Circuit Current detected at injector Number 4 when voltage is turned off Current to injector is shut off Engine can possibly misfire or run rough 629 12 Electronic Control Module Warning Internal Hard ware Failure Bad Intelligent Device or Component ECM power supply errors have been detected Possible no noticeable performance eff...

Page 79: ... Possible white smoke loss of power or hard starting 639 9 J1939 Datalink Abnormal Update Rate Communication between the electronic control module ECM and another device on the SAE J1939 data link has been lost Engine speed will ramp down and remain at idle 97 3 Water in Fuel Indicator Sensor Circuit Voltage Above Normal or Shorted to High Source High voltage detected at the water in fuel circuit ...

Page 80: ... pressure has exceeded the maximum limit for the given engine rating The engine may be derated 157 3 Injector Metering Rail Number 1 Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source High signal voltage detected at rail fuel pressure sensor circuit Power and or speed derate 157 4 Injector Metering Rail Number 1 Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Sou...

Page 81: ...stimate fuel pressure and power is reduced 101 16 Crankcase Pressure Data Valid but Above Normal Operational Range Moderately Severe Level The crankcase breather filter requires maintenance None on performance 101 0 Crankcase Pressure Data Valid but Above Normal Operational Range Most Severe Level The crankcase breather filter requires maintenance Engine power derate 94 18 Injector Metering Rail 1...

Page 82: ...il low battery voltage condition is corrected 167 1 Electrical Charging System Voltage Data Valid but Below Normal Operational Range Most Severe Level Very low battery voltage detected by the battery voltage monitor feature Red lamp illuminated until very low battery voltage condition is corrected 1378 31 Engine Oil Change Interval Condition Exists Change engine oil and filter Maintenance reminder...

Page 83: ...bove Normal or Shorted to High Source High signal voltage detected at the turbocharger compressor inlet air temperature circuit Engine power derate 1172 4 Turbocharger 1 Compressor Inlet Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source Low signal voltage detected at the turbocharger compressor inlet air temperature sensor circuit Engine power derate 1136 3 ECM Internal Temp...

Page 84: ... Data Erratic Intermittent or Incorrect Loss of communication with adaptive cruise control Adaptive cruise control will not operate Standard cruise control may not operate 627 2 Power Supply Lost With Ignition On Data Erratic Intermittent or Incorrect Supply voltage to the ECM fell below 6 2 volts momentarily or the ECM was not allowed to power down correctly retain battery voltage for 30 seconds ...

Page 85: ...atalyst in the exhaust system is not present Active aftertreatment diesel particulate filter regeneration will be disabled 3241 4 Aftertreatment Exhaust Gas Temperature 1 Circuit Voltage Below Normal or Shorted to Low Source Low signal voltage detected at the catalyst inlet sensor circuit Active aftertreatment diesel particulate filter regeneration will be disabled 3241 3 Aftertreatment Exhaust Ga...

Page 86: ...ermittent or Incorrect The aftertreatment diesel particulate filter inlet temperature sensor is not changing with engine operating conditions Active aftertreatment diesel particulate filter regeneration will be disabled 3050 13 Catalyst Efficiency Out of Calibration The temperature increase across the aftertreatment diesel oxidation catalyst is lower than expected None on performance 3513 3 Sensor...

Page 87: ...r failed the auto zero test EGR valve actuation will be disabled 3245 3 Aftertreatment Exhaust Gas Temperature 3 Circuit Voltage Above Normal or Shorted to High Source High signal voltage detected at the catalyst inlet temperature sensor circuit None on performance 3245 4 Aftertreatment Exhaust Gas Temperature 3 Circuit Voltage Below Normal or Shorted to Low Source Low signal voltage detected at t...

Page 88: ...ulate Filter Differential Pressure Sensor Data Erratic Intermittent or Incorrect The aftertreatment diesel particulate filter differential pressure sensor is reading an erratic value at Initial key on or during engine operation Active aftertreatment diesel particulate filter regeneration will be disabled 2791 13 EGR Valve Controller Out of Calibration The EGR valve has failed the automatic calibra...

Page 89: ...has exceeded the recommended limits The aftertreatment dash lamp will flash Engine protection derate 3251 0 Aftertreatment Particulate Filter Differential Pressure Data Valid but Above Normal Operational Range Most Severe Level The soot load of the aftertreatment diesel particulate filter has exceeded the recommended limits Severe engine derate 3597 18 ECU Power Output Supply Voltage 1 Data Valid ...

Page 90: ... the maximum temperature limit Active aftertreatment diesel particulate filter regeneration will be disabled 3249 0 Aftertreatment Exhaust Gas Temperature 2 Data Valid but Above Normal Operational Range Most Severe Level The aftertreatment diesel particulate filter inlet temperature sensor reading has exceeded the maximum engine protection temperature limit Engine power derate Active aftertreatmen...

Page 91: ...aftertreatment differential pressure has exceeded the maximum operating limits or the diesel particulate filter is plugged Active aftertreatment diesel particulate filter regeneration will be disabled 3064 31 Aftertreatment Particulate Trap Missing Condition Exists The aftertreatment diesel particulate filter in the exhaust system is not present Active aftertreatment diesel particulate filter rege...

Page 92: ...cted at the EGR position sensor circuit EGR valve actuation will be disabled 411 3 Exhaust Gas Recirculation Valve Delta Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source High signal voltage detected at the EGR differential pressure sensor circuit EGR valve actuation will be disabled 411 4 Exhaust Gas Recirculation Valve Delta Pressure Sensor Circuit Voltage Below Normal or Sh...

Page 93: ...er 1 Speed Abnormal Rate of Change The turbocharger speed sensor has detected an erroneous speed value None on performance The ECM uses an estimated turbocharger speed 2789 15 Turbocharger Turbine Inlet Temperature Calculated Data Valid but Above Normal Operational Range Least Severe Level Turbocharger turbine inlet temperature has exceeded the engine protection limit Fuel is limited in an attempt...

Page 94: ...ndicating a stuck open EGR valve EGR valve actuation will be disabled 411 16 Exhaust Gas Recirculation Valve Delta Pressure Data Valid but Above Normal Operational Range Moderately Severe Level The EGR differential pressure sensor has detected high EGR gas flow or the EGR differential pressure reading is not valid for engine operating conditions EGR valve actuation will be disabled 1209 3 Exhaust ...

Page 95: ...Responding Properly or Out of Adjustment The smart VGT controller has detected incorrect stop limits or the VGT is unable to move to the closed position VGT travel may be limited 111 17 Coolant Level Data Valid but Below Normal Operational Range Least Severe Level Low engine coolant level detected None on performance 641 13 VGT Actuator Controller Out of Calibration The VGT has failed the automati...

Page 96: ...rror has been detected by the smart VGT controller VGT actuation will be disabled 641 31 VGT Actuator Driver Circuit Condition Exists A calibration mismatch between the VGT actuator and the ECM has been detected VGT actuation will be disabled 641 9 VGT Actuator Driver Circuit Abnormal Update Rate No communications on the J1939 datalink between the engine ECM and the smart VGT controller VGT actuat...

Page 97: ...Normal Operational Range Moderately Severe Level Excessive fuel injection into the aftertreatment system has been detected None on performance 3249 17 Aftertreatment Exhaust Gas Temperature 2 Data Valid but Below Normal Operating Range Least Severe Level The temperatures in the aftertreatment system can not reach the required temperatures for stationary regeneration None on performance 3249 17 Aft...

Page 98: ...aust Gas Recirculation Temperature Data Valid but Above Normal Operational Range Moderately Severe Level EGR temperature has exceeded the engine protection limit Severe fueling derate to bring EGR temperature under the maximum limit 110 15 Engine Coolant Temperature Data Valid but Above Normal Operational Range Least Severe Level Engine coolant temperature is above the engine coolant temperature e...

Page 99: ... cycle between three codes as listed in Table 4 4 c To advance to the next code press the MODE button for approximately three seconds 102 2 Intake Manifold 1 Pressure Data Erratic Intermittent or Incorrect The ECM has detected an intake manifold pressure signal that is too high or low for current engine operating conditions Engine power derate Table 4 4 Transmission Diagnostic Codes Code Descripti...

Page 100: ...8 Actuator Supply Yes DNS SOL OFF hydraulic P0659 Actuator Supply Yes DNS SOL OFF hydraulic P0702 Transmission Control Yes Uses TID A calibration P0703 Brake Switch Circuit Malfunction No No Neutral to Drive shifts for refuse packer TCM inhibits retarder operation if a TPS code is also active P0708 Transmission Range Yes Ignore defective strip P070C Transmission Fluid No None P070D Transmission Fl...

Page 101: ...h then P0734 Incorrect 4th Gear Yes DNS Attempt 5th then P0735 Incorrect 5th Gear Ratio Yes DNS Attempt 6th then 3rd then 2nd P0736 Incorrect Reverse Gear Yes DNS Lock in Neutral P0741 Torque Converter Yes None P0776 Pressure Control Yes DNS RPR P0777 Pressure Control Yes DNS RPR P0796 Pressure Control Yes DNS RPR P0797 Pressure Control Yes DNS RPR P0842 Transmission Pressure Yes DNS Lock in curre...

Page 102: ...NS SOL OFF hydraulic P0975 Shift Solenoid 2 SS2 Yes 7 speed Allow 2 through P0976 Shift Solenoid 2 SS2 Control Circuit Low Yes 7 speed Allow 2 through 6 N R Inhibit TCC P0977 Shift Solenoid 2 SS2 Yes 7 speed Allow 2 through P0989 Retarder Pressure No None P0990 Retarder Pressure No None P1739 Incorrect Low Gear Ratio Yes Command 2nd and allow shifts 2 through 6 N R P1891 Throttle Position No Use d...

Page 103: ...efault P2729 Pressure Control Yes DNS SOL OFF hydraulic P2730 Pressure Control Solenoid 1 PCS1 Yes DNS SOL OFF hydraulic default P2736 Pressure Control Solenoid 5 PCS5 Yes Inhibit retarder operation P2738 Pressure Control Solenoid 5 PCS5 Yes Allow 2 through 6 N R Inhibit retarder and TCC P2739 Pressure Control Solenoid 5 PCS5 Yes Inhibit retarder operation P2740 Retarder Oil No None P2742 Retarder...

Page 104: ...0100 Lost Communications Yes Use default values U0103 Lost Communication With Gear Shift Module Yes Maintain range selected observe gear shift U0115 Lost Communication Yes Use default values U0291 Lost Communication With Gear Shift Module Yes Maintain range selected observe gear shift U0304 Incompatible Gear Yes Ignore shift selector inputs U0333 Incompatible Gear Yes Ignore shift selector inputs ...

Page 105: ...e dash will blink in a specific pattern Figure 4 3 shows an example of a blink code The system may display more than one code Be sure to read and record all codes Refer to Table 4 5 to interpret the diagnostic blink codes a Stop vehicle and apply parking brake b Turn ignition key to ON c Press and hold the diagnostic button for at least one sec ond but not more than three seconds d Record the two ...

Page 106: ...open 2 7 Internal error at sensor port of ECU 2 8 Sensor found in wrong location for system configuration 3 1 Sensor air gap too large 3 2 Air gap too large or sensor shorted 3 3 Speed sensor noisy 3 4 Wheel locked for excessive period of time during an ABS cycle 3 5 Excessive rate of deceleration found at wheel site or sensor shorted 3 6 Sensor connection shorted low or high or sensor open 3 7 In...

Page 107: ... error at sensor port of ECU 6 8 Sensor found in wrong location for system configuration 7 1 Sensor air gap too large 7 2 Air gap too large or sensor shorted 7 3 Speed sensor noisy 7 4 Wheel locked for excessive period of time during an ABS cycle 7 5 Excessive rate of deceleration found at wheel site or sensor shorted 7 6 Sensor connection shorted low or high or sensor open 7 7 Internal error at s...

Page 108: ...pply voltage 11 2 Short between release solenoid and ground 11 3 Open circuit at release solenoid 11 4 Open circuit in common line to valve 11 5 Short between hold solenoid and supply voltage 11 6 Short between hold solenoid and ground 11 7 Open circuit at hold solenoid 11 8 Valve found wired in wrong location 11 10 Diagonal 2 common side of valves SR LR LRR shorted to bat 11 11 Diagonal 2 common ...

Page 109: ...al fault 15 4 ECU internal fault 15 5 ECU internal fault 15 6 ECU internal fault 15 7 ECU internal fault 15 8 ECU internal fault 15 10 ECU internal fault 15 11 ECU internal fault 16 1 Excessive voltage on diagonal pin 1 Pin A 9 16 2 Low voltage found on diagonal pin 1 Pin A 9 16 3 No voltage found on diagonal pin 1 Pin A 9 16 4 No ground found on diagonal pin 2 Pin A 11 16 5 Excessive voltage on d...

Page 110: ...oning 17 4 J1922 939 date link time out 17 5 Tire size front to rear out of range 17 6 Tire size out of range or parameter fault 17 7 Brake light switch not pushed at this power cycle 17 8 ATC system disabled for dynamometer test 17 12 Sensor fault memory bit is set Drive vehicle above 5 mph to clear Table 4 5 ABS Diagnostic Codes Cont Digit 1 Digit 2 Description ...

Page 111: ...cation Recommendations Frequency Item Lubricant Fluid Daily Fifth Wheel Surface NLGI 00 Grease Oscillation Shaft 2 pl NLGI 00 Grease Boom Pivot Shaft 2 pl NLGI 00 Grease Slack Adjusters 2 front 2 rear NLGI 00 Grease Monthly or 200 Hrs Rear Axle Synthetic Gear Lube Dura Ride Pivot Shaft NLGI 00 Grease Brake Camshaft 2 front 2 rear NLGI 00 Grease Lift Cylinder NLGI 00 Grease Prop Shaft Multipurpose ...

Page 112: ......

Page 113: ... 10 gal 37 85L Recommended Fluid Chevron AW 32 or equal Anti wear anti foam 10 15W Power Steering Fluid Capacity 4 qts 3 78L Recommended Fluid Dexron III Automatic Transmission Fluid Tilt Cab Pump Fluid Capacity 2 qts 1 89L Recommended Fluid Dexron III Automatic Transmission Fluid Engine Cummins QSB T3 6 7L Elite 167 HP EPA Industrial Turbo Diesel Transmission Model Allison RDS3000 Electronic Auto...

Page 114: ...322I 13 2000 lb Rear Axle Model Eaton 23 170 7 17 1 ratio Recommended Fluid SAE 80W 90 Gear Oil Capacity 41 pints 19 4L Engine Cummins ISB07 220 HP EPA Highway Turbo Diesel Transmission Model Allison RDS3000 Electronic Automatic Transmission Oil Dexron IV Automatic Capacity 19 qts 18L Front Axle Meritor FF961 12 000 lb Rear Axle Model Meritor RT 44 145 7 17 1 ratio 40 000 lb tandem Recommended Flu...

Page 115: ...lb Rear Axle Model Meritor RS 30 380 10 62 1 ratio 42 000 lb Double Reduction Recommended Fluid SAE 80W 90 Gear Oil Capacity 56 pints 26 46L Engine Cummins QSB T3 6 7L Elite 183 HP EPA Industrial Turbo Diesel Transmission Model Allison RDS3000 Electronic Automatic Transmission Oil Dexron IV Automatic Capacity 19 qts 18L Front Axle Dana E1462I 14 600 lb Rear Axle Model Sisu SRDP 30 S 12 28 1 ratio ...

Page 116: ...ission Compliant Transmission Model Allison RDS3500 Electronic Automatic Transmission Oil Dexron IV Automatic Capacity 19 qts 18L Front Axle Dana E1462I 14 600 lb Rear Axle Model Sisu SRDP30S 12 28 1 ratio 70 000 lb Planetary Reduction Recommended Fluid SAE 80W 90 Gear Oil Capacity 38 pints 17 9L ...

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